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1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072
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INVESTIGATIVE ANALYSIS ON THE IMPACT OF ZIRCONIA COATING ON
FATIGUE LIFE OF AISI 316L STEEL
NOONE AVINASH1, SAMPATH PAMPANA2
1 M.Tech Student, Dept. of Mechanical Engg., Vidya Jyothi Institute of Technology, Hyderabad, India
2 Associate Professor, Dept. of Mechanical Engg., Vidya Jyothi Institute of Technology, Hyderabad, India
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Abstract - AISI 316L steel is extensively used in marine application such as boat rails and hardware, facades of buildings,
pharmaceutical and bio-processing, dairy and food, brewery and other beverage industries due to high corrosion and heat
resistance along with outstanding fabricability and formability.
In the present work, the effect of Zirconia powder coating on the fatigue life and corrosion resistance of AISI 316L
steel was examined. The characterization of base material and coating is done in terms of chemical composition,
microstructure, surface roughness and hardness. Thereafter, low cycle fatigue tests and corrosion tests are conducted to
examine the fatigue life and corrosion resistance.
It was found that the there was a reduction in fatigue life of the chosen material by around 5% due to the HVOF
coating of Zirconia. However the corrosion resistance can be improved by around 30% due to the same. It is hence a trade-off
conclusion between fatigue life and corrosion resistance, to be taken by engineers based on the application requirements.
Key Words: AISI 316L steel, Zirconia, HVOF coating, Fatigue life, Corrosion resistance
1. INTRODUCTION
Machine is mechanical arrangement which utilises power for applying forces in order to manage movement as
well as other parts which we utilize in on a regular living were frequently undergone to multiple forces enclosed. Stresses
as well as strains formed were occasionally periodic relative to direction of forces. Although degree of strain is less than
their yield limit since they result in failure while they were used a number of schedules at regular intervals. If Material was
undergone to continuous series of stress or else strain, failure happens with foremost towards fracture at a few
deficiencies, this kind of failure was known to be fatigue.
Fatigue deformation was formed with adaptive steps of rotating stress, tensile stress in addition to plastic strain. The
plastic strain happening since cyclical stress initiate crack, tensile stress promote crack increase. Careful calculation of
strain represent to minute plastic strains might be present on low level based on stress since the strain may or else emerge
into completely elastic. Even if compressive stresses mayn’t reason fatigue failure, Compressive loads will induce local
tensile stresses. This was required for implementing few steps for developing fatigue life for components also with varying
geometry for components otherwise decreasing Resistance divergent close to material. Geometry adjust was never
answer, particularly because of a few limitations. Thus fatigue life for element was raised with reducing strains of
substance. Several methods like heat treatment, coating etc., will improve fatigue life for substance yet beneath study all of
us have to move ahead within consideration strains.
2. EXPERIMENTAL DESIGN
2.1. Material
Stainless steels were low carbon alloy steels by chromium being main blend component. Corrosion resistance for steels
was because of presence for a considerable amount for chromium which creates formation for skinny, effective deposit for
chromium-oxide that defends exterior among decay.
AISI 316L Austenitic Stainless Steel was substance where corrosion resistance, fatigue life were analyzed over
project. The Steel was mainly utilized for naval as well as marine practices since this contains outstanding corrosion
resistance, large strength via weight proportion.

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Table -1: Equipment used during the research study
S.No Equipment
1 High Velocity Oxy-Fuel facility
2 Plug N Play for fatigue testing
2.2 Thermal spray coating
Thermal Spray coating is used globally in defending commercial parts among decay, abrasion, erosion, wear,
surface fatigue, to guard substrates operating in high temperatures. Thermal spray coating procedures were divided as
follows: plasma spray Process, flame thermal spray, high velocity oxy fuel (HVOF) spraying, cold spraying, arc spray
process, and detonation gun method. In the current project, the selected component was laminated by ZrO2 using high-
velocity oxy-fuel coating apparatus. ZrO2 was moved across central orifice of Torch, fuel gas combined by oxygen pass via
channel for Torch. Later becoming warmed near end of Torch, molten ZrO2 was sprinkled over job in order this is sprayed
over specimen.
Fig -1: HVOF coating equipment
2.3. Fatigue Testing Machine
Plug-N-Play Fatigue Testing Machine in ITW was used to detect fatigue life for specimens. Apparatus consist of condition
for using different Tensile, Compressive important reversed loads. This was given by computer data logger for notify
amount of series enforced throughout Test.
Fig -2: Specimen mounted on the Plug-N-Play Fatigue Testing Machine
2.4 Test Specimens and types used in experimental work
(1) Uncoated Specimens
Solid round samples are used for Low fatigue tests. Tests are done for calculate Low cycle fatigue life analysis on
uncoated material.
Material Type
Uncoated AISI 316L Specimens Round solid bars

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Figure 3: Uncoated AISI 316L Specimens
(2) Zirconia Coated specimens
Chosen amount for samples containing Solid round bar fatigue samples of type AISI 316L Stainless steel are shop
cut to required length and diameter. The size included 66 mm length through the complete specimen diameter of 10mm
thickness. The complete specimens are prepared accordingly by ASTME 606 – 92 (Reapproved 1998) Standard. The
properly machined investigation samples are subjected to HVOF spraying with zirconia powders.
Material Type Number of coated specimens
300 microns Zirconia coated AISI 316L Specimens Round solid bars 3
Figure 4: 300 microns AISI 316L specimens just sprayed with the coating powder.
2.5 LCF test on specimens
Initially the specimens are placed on to Plug N play Fatigue testing apparatus .The Specimens are gripped into the
jaws and locked tightly.
Table 2: Plug N Play Fatigue testing parameters
Load capacity 3 KN
Cyclic wave forms Sine, Triangle, Square, HSine, HTriangle and HSquare
Ramp waveform Single, Dual and Trapezoidal
Frequency range 0.4 Hz
Gap among columns 400mm
Testing type Low Cycle Fatigue
Drive unit Hydraulic System
Amplitude 250 Mpa
Mean 0

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2.6 Fatigue Specimen
Samples were made according to ASTM E606 grades by means of CNC lathe.
Figure 5: Specimen geometry used for fatigue tests.
2.7. Finite Element Fatigue Analysis
Finite Element Method was done for calculate Fatigue or Tolerance barrier for selected components, for estimating ‘Stress
(vs.) Fatigue Life’ arc. ANSYS 18.1 was utilized like instrument in order for carry out Finite Element Analysis. Strain life
approach obtainable over ANSYS 18.1 Fatigue instrument was used to analysis. Strain-Life method extracts for
consideration, local plastic strains brought at localized points.
3. FINITE ELEMENT AND EXPERIMENTAL INVESTIGATIONS
3.1. Stress (vs) Fatigue Life Curve through Finite Element Approach
Tolerance limits, Stress (vs.) Fatigue Life curve are calculated by ANSYS 18.1. For replicate circumstances for trial
conducted, axial load with form for outward pressure is kept over right face, permanent assist is given to left face for
sample.
Figure 6: Boundary Conditions used for the analysis
Parameters utilized for finite element fatigue analysis for AISI 316L in ANSYS:
Modulus of Elasticity (E) = 193 GPa
Poisson’s Ratio (µ) = 0.27
Tensile Strength (UTS) = 719 MPa
Fatigue Strength Coefficient = 1078.5 MPa (taken as 1.5*UTS for steels)
Fatigue Strength Exponent (b) = -0.087 (standard value of steels)
Fatigue Ductility Coefficient = 0.59 (standard value of steels)
Fatigue Ductility Exponent (c) = -0.58 (standard value of steels)
Cyclic Strain Hardening Exponent (n') = 0.15 (taken as b/c)
Cyclic Strength Coefficient (K') = 1167.21 MPa (taken as ( )
⁄ )

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Figure 7(a): Normal stress in x-direction Figure 7(b): Fatigue Life in cycles
Finite element fatigue runs were taken among 40 variable loadings, the stress (vs) fatigue life curve was drawn
through corresponding stress, fatigue life results. Table 4.1 encloses stress, fatigue life values also curve was drawn in
Figure 4.4. Magnified direction for Low cycle fatigue area for stress (vs.) fatigue life curve was revealed in Figure 4.5.
Tolerance boundary was seen as 321.45 MPa of AISI 316L because this was stress value got over fatigue life for nearly 106
cycles. Equivalent will be seen over bold line of Run 2 in below Table.
Table 3: Finite Element Fatigue results for AISI 316L
Run Pressure (MPa) Normal Stress of X-direction (MPa) Fatigue Life (cycles)
1 110.5 319.98 1045300
2 111.01 321.45 1000700
3 115 333.01 720080
4 120 347.48 490440
5 125 362.94 343930
6 130 377.46 247690
7 135 391.84 182760
8 140 406.46 137830
9 145 420.84 106040
10 150 435.48 83030
11 155 449.82 66080
12 160 464.32 53360
13 165 478.70 43667
14 170 493.28 36155
15 175 507.76 30256
16 180 522.24 25567
17 185 536.72 21798
18 190 551.19 18734
19 195 565.67 16210
20 200 570.13 14138
21 205 584.81 12390
22 210 609.13 10938
23 215 623.59 9699

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24 220 638.06 8642
25 225 652.54 7735
26 230 667.02 6952
27 235 681.46 6273
28 240 695.98 5670
29 245 700.46 5169
30 250 724.94 4705
31 255 748.48 4301
32 260 753.84 3943
33 265 768.13 3624
34 270 782.85 3330
35 275 797.33 3085
36 280 811.84 2855
37 285 826.29 2649
38 290 830.76 2462
39 295 855.24 2292
40 300 869.72 2138
3. CONCLUSIONS
From the above research, it can be concluded that the Endurance limit value obtained from finite element method is
accordance by real value for components. For AISI 316L, tolerance limit through finite element process (ANSYS 18.1)
result was 321.45 MPa. Hence we can conclude that Finite Element Method can approximate the endurance limit with
good accuracy. It can also be concluded that the Coating of ZrO2 over AISI 316L steel decreased fatigue life by 5%. HVOF
coating method done, created oxide films evolution over foundation substance AISI 316L, as a result decreased their
fatigue life. Therefore, this was trade-off conclusion among fatigue life as well as corrosion resistance through engineering
design stand point.
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7. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 10 | Oct 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 758
[8] P. Lassen, T. Récho, N. Darcis, “Statistical Models for Fatigue Life General Considerations for the S-N
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